Design Book: Certification, Operating, Installation & Maintenance Manual

Transcription

1 UNIT API SERIAL NUMBER 4650 MODEL SIX STATION MANUFACTURED FOR APPLIED MACHINERY CONTROL SYSTEM FOR SURFACE MOUNTED BOP SYSTEMS Design Book: Certification, Operating, Installation & Maintenance Manual MANUFACTURED BY - - Consolidated Pressure Control, LLLP 7614 Bluff Point Houston TX Voice FAX API LICENSE 16D-0028 DATED MANUFACTURE 07/11

2 Foreword This document and data contained here are constructed under the direction provided by API 16-D, beginning in section 4 General Control System Design Requirements. All data provided and assembled under the direction of the President, assisted by the General Operations Manager. As in all documents of this origin, input by the QA/ QC Coordinator was solicited under the guidelines of requirements outlined in Specification 8 Manufacture Processes. All personnel involved in the assembly and testing of this unit has received hours of training in proper assembly and item testing. The desire of Consolidated Pressure Control LLLP is to provide a quality BOP Control System for years of continued service. C PC QA - Accepted / Approved T. Thornhill - API/ISO Coordniator Tim Thornhill API / ISO Coordinator 2

3 TABLE OF CONTENTS Section 1 - Sizing Unit / Design Input Requirements Section 2 - System Rated Working Pressure Section 3 -Temperature Rating & Environment Classifications Section 4 - Drawings Section 5 - Utilities Consumption List Section 6 - Applicable Standards and Specifications Section 7 - Equipment Location Designations Section 8 - Design Plan Section 9 Sales Data Section 10 - Design Validation Section 11 - Test Procedures Section 12 - Certifications & Manufacturing Checklist Certificate of Conformance API Certificate ISO Certificate Certificate of Conformance Electrical Certificate of Warranty Certificate of Origin Factory Acceptance & Hydrostatic Test Certifications Assorted Component Level Certifications Assembly Procedures & Manufacture Checklist Section 13 - Thing to Know Before Using BOP Accumulator System Location & Positioning Identify Nameplate Section 14 - Understanding Key Components on a BOP Accumulator System Main Components Accumulator Key Component Figures Section 15 - Installing BOP Accumulator System Identify Initial Plumbing and Air Hookup Filling Reservoir and Recharge Bottles

4 TABLE OF CONTENTS Section 16 - Installing Driller Remote Connecting Electrical Power Getting started Powering up PLC Start Up and Selecting Configuration Correct configuration and two hand operation Identify Illumination Understanding Shear Ram Operation Raising and Lowering Annular Section 17 - Starting and Operation Initial Procurers Using Motor Correctly Correct Belt Rotation Priming a CPC Triplex Operation of Nitrogen Back-up (optional) Section 18 - Operation of a Diverter System Rigging Down Section 19- Rigging Down Accumulator Port and Starboard Section 20 - Maintenance and Maintaining BOP Accumulator System Introduction for maintenance Pressure Gauges Reservoir & PRV check / Dryer & Lubricator Control Manifold / Bottle Nitrogen charge Triplex Lubrication / Timing Belt Strainers Section 21 - Extra Information Recommended Maintenance Schedule Accumulator Pressure Chart Do s and Don ts on System Quick Sizing Bottle Dimensions Section 22 - Glossary Key Component Definitions Section 23 - Key Component Parts 4

5 SIZING OF THE UNIT, CAPACITY AND CALCULATIONS 7614 Bluff Point Houston, Texas cpcmfg.com 5

6 Sizing of the Unit & Design Input Requirements 1 Control Systems Design Requirements Specifications pertaining to Operating and Interface Requirements for Surface BOP Systems follow per API: 1.1 System Design for Customer: SIX Station Land Rig Application 1.2 Regular Agency Compliance: YES/NO Name of Agency: API 1.3 BOP Configuration for Customer: Applied Machinery 1.4 BOP Stack Configuration (see table below) Control Fluid Requirements Annular Preventer Pipe Blind Pipe Choke Pipe Type & Size Shaffer 13 5/ psi Shaffer 13 5/ psi Shaffer 13 5/ psi Shaffer 13 5/ psi Shaffer Flo Shear 4-1/ psi Shaffer Flo Shear 4-1/ psi Close Gals Open Gals Close Ratio Open Ratio Volume :1 3.48: :1 3.48: :1 3.48: Total Gallons (min) Control Fluid Requirements Type & Size Close Gals Open Gals Close Ratio Open Ratio Volume Diverter Hydrill MSP 21-1/ psi Total Gallons (min) 6

7 Sizing of the Unit & Design Input Requirements 1.5 Pressure and Volume Requirements (see tables below) Available control fluid volume to close against zero wellbore pressure Nominal system Working Pressure (P work ) Nominal Precharge Pressure (P prech ) Nominal Accumulator bottle volume (Vol acc ) 3000 psia (usually 3015 psi) 1000 psia (usually 1015 psi) 11 gallons per bottle Number of accumulator bottles 24 each Fluid/Bottle (P work to P prech ) = ( Vol acc -1) ( 1 - P prech / P work ) Fluid/Bottle (P work to P prech ) = ( 11-1) ( / 3000) = Gallons Available Accumulator Fluid = Number of Bottles * Fluid / Bottle = Value 24 * = Gallons (min) 1.6. Total Control Functions Required: Hydraulic Pump Systems Required: 2 A. Electric Powered: QTY 1; Size: 14 GPM; Working Pressure: 3,000 PSI Electric Requirements: 25 HP. Volts 480 Amperes: 28 Type XP Grade N/A B. Air Powered: QTY 3: Size: 40: (8-1/2 ) 15 GPM; Working Pressure: 3,000 PSI Air Pressure: 125 PSI CFM Remote Panel: Quantity 2 Area Classification: Pneumatic Air Remote 1.9. Master Panel: Standing 1.10 Type: Wall Mounted Free Standing 1.11 Station Requirements: By-Pass: Yes/No 1.13 Failsafe: Yes/No 7

8 Sizing of the Unit & Design Input Requirements 1.14 Cover for Blind Operating Valve: Yes/No 1.15 Identification for Each Valve: Yes/No 1.16 Lubricator System for Panel: Yes/No 1.17 Type of Panel and Unit Environment: Tropical H 140 L 32 Mild H 120 L 20 Cold H 120 L -4 Extreme H 120 L -23 Polar H 120 L 40 Crucial Controlled Environment 1.18 Operating Pressure Required: 3,000 PSI Review by: Doug Miller Sales Manager Ryan Inderwiesen Drafter Designer 8

9 SYSTEM RATED WORKING PRESSURE 7614 Bluff Point Houston, Texas cpcmfg.com 9

10 System Rated Working Pressure Subsection E System Rated Working Pressure 3,000 PSI Reservoir and Reservoir sizing: 450 Gallons Pressure Rating: Atmosphere Hydraulic control Manifold: Normal Working Pressure 1,500 PSI Maximum Working Pressure 3,000 PSI Tested Pressure: 4,500 PSI Isolation Valve Provided on the HCM Tested Pressure 4,500 PSI Two Independent Pressure Control circuits Provided Common Pressure Control Manifold: A. Subsystem for low manifold pressure to the ram Preventers; 1. Normal working Pressure: 1,500 PSI 2. Maximum working Pressure: 3,000 PSI 3. Tested Pressure: 4,500 PSI Annular BOP control Manifold: A. Dedicated Pressure regulator for the annular BOP. B. Remote control provided with manual override. 1. Normal working Pressure: 750 PSI 2. Maximum working Pressure: 1,500 PSI 3. Tested Pressure: 4,500 PSI Hydraulic control Valves: A. All Valves placed in the block position for pressure 1. Normal working Pressure: 1,500 PSI 2. Maximum working Pressure: 3,000 PSI 3. Tested Pressure: 4,500 PSI Remote Control Panel Pneumatic fully functional drillers remote BOP Control V, Fittings, Lines and Manifold 1. Normal working pressure 1,500 PSI 2. Maximum working Pressure 3,000 PSI 3. Maximum Tested pressure 4,500 PSI Pressure Rating: Normal Working Pressure Piping System: Standard requirements: NPT for piping with ANSI B31.3 fittings Electrical Power Supplies, provided by a UPS for a period of 2.5 hr. 10

11 TEMPERATURE RATINGS & ENVIRONMENT CLASSIFICATION 7614 Bluff Point Houston, Texas cpcmfg.com 11

12 Temperature rating and environment classification of subsystems 5.1 Control systems for surface-mounted BOP stacks. A. Storage 310 Maximum Capacity: Environment classification: Mild Ambient Temperature Classification: High 120 Low 20 B. Pumping Systems: 1. Pneumatic pump system: Environment classification: Mild Ambient Temperature Classification: High 120 Low Triplex pump system: Environment classification: Mild Ambient Temperature classification: High 120 Low 20 C. Accumulator bottles: Environment classification: Mild Ambient Temperature classification: High 120 Low 20 D. Hydraulic Control Manifold: Environment classification: Mild Ambient Temperature classification: High 120 Low 20 E. Remote control panel: Environment classification: Mild Ambient Temperature classification: High 120 Low 20 F. Hydraulic control fluid*: Environment classification: Mild Ambient Temperature classification: High 120 Low 20 *See Attached Specifications and MSDS* 12

13 DRAWINGS Drawings and Calculations to Document Compliance to Specifications 7614 Bluff Point Houston, Texas cpcmfg.com 13

14 Drawing APPLIED MACHINERY Acc Press Switch 2-4A 2-4B Air Press Switch 2-5A 2-5B Hyd Level Switch 2-6A 2-6B SWITCHES ARE OPEN WHEN FAULT IS NOT PRESENT SWITCHES EXTERNAL TO PANEL CUSTOMER SUPPLIED 480V 3PH 60HZ FU2 FU3 FU4 + MOTOR 1 25HP 1800RPM 480\3\60 L1 L2 L3 PE 0V CR V Inputs Outputs +24 1M M M L+ 1M 1L Gnd 2M 2L+ 0VDC +24 A1 CR2 A2 POWER SUPPLY PULS SL P 480VAC TO 24VDC FU1 - Siemens 222 PLC 6ES AB23-OXBO VDC VDC A1 CR1 A2 CR R R R 2-7A 2-7B BEACON 3-1 Low Acc Light PIN1 3-2 Low Air Light PIN2 3-3 Low Level Light PIN3 3-4 Horn PIN 4 R R R 3-5 Alarm Ackn. PB PIN VDC PIN VDC PIN 7 (Alarm Silence) HOLD FOR 3 SEC. FOR LAMP TEST To Remote Panel A1 M1 A2 HOA OL1 Consolidated Pressure Control DRAWN BDS UPDATED ENGINEER Applied Machinery 6 Station Alarm/Starter Combo Job #3346 SIZE A DWG NUMBER APPROVED JDN Applied Machinery SKID_4650 SCALE 1 : 1 REV 0 SHEET 1 OF 1 14

15 Drawing APPLIED MACHINERY D D C C B B DRAWN GR 8/31/2011 CONSOLIDATED PRESSURE CONTROL CHECKED RI 8/31/2011 TITLE A QA A 4 3 MFG GK APPROVED RI 2 8/31/ STATION AIR REMOTE WITH DIVERTER AND ALARMS DRILLER 8/31/2011 DWG NO SIZE C SCALE AR06S-4GDIV-ALM-DR-1 SHEET 1 OF 1 1 REV 01 15

16 Drawing APPLIED MACHINERY D D C C B B DRAWN GR 8/31/2011 CONSOLIDATED PRESSURE CONTROL CHECKED RI 8/31/2011 TITLE A QA A 4 3 MFG GK APPROVED RI 2 8/31/ STATION AIR REMOTE TOOLPUSHER WITH DIVERTER 8/31/2011 DWG NO SIZE C SCALE AR06S-4GDIV-TP-1 SHEET 1 OF 1 1 REV 01 16

17 Drawing APPLIED MACHINERY SHEET 1 OF 1 1 8/31/2011 DWG NO SIZE C SCALE S06S-11TL AR GK APPROVED RI REV 8/31/2011 MFG 6 STATION UNIT WITH DIVERTER AND ALARMS DRAWN GR 8/31/2011 CONSOLIDATED PRESSURE CONTROL CHECKED RI 8/31/2011 TITLE A QA A B B C C D D

18 UTILITES CONSUMPTION LIST 7614 Bluff Point Houston, Texas cpcmfg.com 18

19 Utilities Consumption List Pump System Electrical Requirements APPLIED MACHINERY A. Electrical operated pump system including the suction and dis-charge manifolds operated through two pressure control devices. B. Electrical requirements: 25HP 3PHASE 480VOLTZ 60HZ 28 AMPS Air Operated Pump System A. Air Pumps require 125 psi to operate to full capacity, reserve air tank will supply air for remote operated valve control B. Air requirements: 3X 40:1 (8-1/2 ) 160 CFM Remote Control Panels A. Air operating of the air cylinders from the remote panel is accomplished through the Touch screen Panels, via an Ethernet cable to the control system mounted within the confines if the skid of the unit. In addition the 120 VAC will supply remotes with 24 VDC circuit with air supply line. 19

20 SECTION 6 APPLICABLE STANDARDS AND SPECIFICATIONS 7614 Bluff Point Houston, Texas cpcmfg.com 20

21 Applicable Standards And Specifications 5.0 API 16D and RP Control Systems for Surface Mounted BOP Stacks A. Storage equipment required for supplying ample control fluid to the pumping system. System requirements: 157 of useable fluid Supplied: 253 B. Pumping systems for pressurizing the control systems: 1. Electrical pumping system ,000 PSI a. Electrical motor b. Belt drive assembly c. Suction manifold d. Discharge manifold 2. Pneumatic pumping system ,000 PSI a. air operated b. Suction manifold c. Discharge manifold Total 3,000 PSI 3,000 PSI Total Time 3,000 PSI 11 MIN 253 gals. Actual Time 3,000 PSI 9.30 MIN 3. Each system equipped with two pressure control devices C. Accumulator bottles: 1. Requirements: 157 Gallons of Useable Fluid 2. Supplied: 253 Gallons of Useable Fluid D. Hydraulic control manifold for regulating the control fluid pressure and directing the power fluid flow to operate the system functions (BOP s and choke and kill valve) 1. One valve manifold system for controlling the manifold selector valves. Equipped with manual operating regulator with an established by-pass valve for pressure selection. 2. One manifold system for controlling the annular selector valve. Equipped with independent regulator for remote control operation. 21

22 Applicable Standards And Specifications E. Remote control panel for operating the hydraulic control manifold from a remote location. Equivalent to the unit control system. Unitized with an umbilical. 1. Remote panel with selector valves, and equipped with adjustment for the annular regulator, and by-pass selector valve Response Time: Annular BOP fluid Requirements: Gals. Operating Pressure 700/1500 Calculations based on 700 PSI Closing time:.45 seconds Ram fluid Requirements: Gals Operating Pressure 1500/3,000 Calculations based on 1,500 Closing time:.40 Seconds Each pump is designed to provide a discharge pressure at least equal to the system rated pressure. Air pump is 40:1 with 75 PSI rated pressure is equal to pressure rating of the system see chart Each pump system is protected by over pressurization by a minimum of two (2) devices designed to limit the pump discharge pressure. a. Air pump provided with: 1. hydro-pneumatic pressure switch 2. pressure relief valve b. Electric pump provided with: 1. hydro-electric pressure switch 2. Pressure relief valve Each pump is designed to engage upon start up. a. Air pump pressure switch closes air support line 3,000 PSI. Air pump engages when pressure decreases to 2,500 PSI b. Electric pump switch breaks 3,000 PSI. 2,500 2,600 PSI 22

23 Applicable Standards And Specifications Accumulator Bottles and Manifolds Accumulators provided exceed requirements Each accumulator is AMSE Boiler & Pressure Vessel Code, Section VIII, Div. I Each accumulator is a bladder type Each accumulator is provided with an individual bleed down valve Each accumulator is provided with a pre-charge pressure of 1,000 PSI As Above Accumulator volumetric Capacity Requirements: Section A: See design spec. Compliance Section B: See design spec. Compliance The below list is for applicants Sections Through Periodic Inspection and Maintenance Procedure: See Maintenance document. 23

24 EQUIPMENT LOCATION DESIGNATIONS 7614 Bluff Point Houston, Texas cpcmfg.com 24

25 Equipment Location Designations A. United States (Class I Div. II) 25

26 DESIGN PLAN 7614 Bluff Point Houston, Texas cpcmfg.com 26

27 Design Plan APPLIED MACHINERY Customer: Nabors USA Job Order No: 3346 Design 6-Station BOP Control System (accumulator closing unit) for surface mounted BOP stack (RFQ: DM ) A. Description: Sizing and Capacity: 157 Gallons (450-Gallon Tank) BOP Configuration Fluid Requirements as provided by Nabors USA Control Fluid Requirements Annular Preventer Pipe Blind Pipe Choke Pipe Type & Size Shaffer 13 5/ psi Shaffer 13 5/ psi Shaffer 13 5/ psi Shaffer 13 5/ psi Shaffer Flo Shear 4-1/ psi Shaffer Flo Shear 4-1/ psi Close Gals Open Gals Close Ratio Open Ratio Volume :1 3.48: :1 3.48: :1 3.48: Total Gallons (min) Control Fluid Requirements Type & Size Close Gals Open Gals Close Ratio Open Ratio Volume Diverter Hydrill MSP 21-1/ psi Total Gallons (min) 27

28 Design Plan Pressure and Volume Requirements (see tables below) Available control fluid volume to close against zero wellbore pressure Nominal system Working Pressure (P work ) 3000 psia (usually 3015 psi) Nominal Precharge Pressure (P prech ) 1000 psia (usually 1015 psi) Nominal Accumulator bottle volume (Vol acc ) 11 gallons per bottle Number of accumulator bottles 24 each Fluid/Bottle (P work to P prech ) = ( Vol acc -1) ( 1 - P prech / P work ) Fluid/Bottle (P work to P prech ) = ( 11-1) ( / 3000) = Gallons Available Accumulator Fluid = Number of Bottles * Fluid / Bottle = Value 24 * = Gallons (min) Total Usable Fluid Provided with TWENTY-FOUR (24), ELEVEN (11) Gallon Accumulators: 157 Gallons B. Working pressure: 3,000 PSI C. Temperature rating: 120 F 20 D. Environmental class: MILD E. Location: Land Equipment specs: Reference 16D purchasing information checklist (attached/included is sales data) 28

29 Design Plan APPLIED MACHINERY Order Date: May 2010 Received: May 2011 Requirement Assigned To Completion Approval (Technical Interfaces) Date Signature Review Design Input Doug Miller (List documents or 05/11 Specifications) Create design output Ryan Inderwiesen 05/11 (i.e. drawings, instructions Specifications, etc) Conducted design review Gary Landrum 05/11 Review design output to Design input requirements Design verification Calculation Method A Gary Landrum 07/11 Conduct design validation By testing. (State Testing Method) Hydrostatic test In accordance with API 16d, requirements, See OP Assembly and hydrostatic testing) Tim Thornhill 07/11 29

30 SALES DATA 7614 Bluff Point Houston, Texas cpcmfg.com 30

31 Sales Data APPLIED MACHINERY 7614 Bluff Point Houston, TX Friday, September 23, 2011 To: Applied Machinery Stephanie Vick Quote #: DM Item Description Make and Type Size/Press Close Gals Open Gals Close Ratio Open Ratio Volume 1 Annular Shaffer - Spherical 13-5/8 in psi Pipe Shaffer - LWP Type SL and 13-5/8 in psi :1 3.48: LWS Posilock 3 Blind Shaffer - LWP Type SL and 13-5/8 in psi :1 3.48: LWS Posilock 4 Pipe Shaffer - LWP Type SL and LWS Posilock 13-5/8 in psi :1 3.48: Choke Shaffer - Flo-Seal 4-1/16 in psi Kill Shaffer - Flo-Seal 4-1/16 in psi Select Select Select Select Select Select Select Delete Row Add Row Volume Required = Gals TOTAL ACCUMULATOR VOLUME REQUIRED % Safety Factor (0-100) = Gals Total Usable Volume Required = Gals Fraction of Total Volume that is Usable = Pre-Charge Pressure Minimum Pressure Pre-Charge Pressure Unit Operating Pre-Charge Pressure = 1,000 psi Unit Operating Pressure = 3,000 psi Minimum Pressure = 1,050 psi Bottle Size = 11 Gals 24 Fraction of Total Volume (or of a bottle) that is Usable = ( 1000 / 1050 ) - ( 1000 / 3000 ) = 0.62 Number of 11.0 Gal Total Accumulator Volume Required = / 0.62 = Gals Bottles Required Total Bottles Required = Gals / 11.0 Gals/bottle = 24.0 Bottles 24 This is an API 16D Monogrammed Unit DM Applied Machinery- 6 Station BOP Control Unit with 2 Air Remotes and Alarm Pkg 31 Pag

32 Sales Data Consolidated Pressure Control LLLP APPLIED MACHINERY ACCUMULATOR SIZING Item Description Make and Type Size/Press Close Gals Open Gals Close Ratio Open Ratio Volume 1 Diverter Hydril - MSP 21-1/4 in psi Select Select Select Select Select Select Select Delete Row Add Row Volume Required = Gals TOTAL ACCUMULATOR VOLUME REQUIRED % Safety Factor (0-100) = Gals Total Usable Volume Required = Gals Fraction of Total Volume that is Usable = Pre-Charge Pressure Minimum Pressure Pre-Charge Pressure Unit Operating Pre-Charge Pressure = 1,000 psi Unit Operating Pressure = 3,000 psi Minimum Pressure = 1,050 psi Bottle Size = 11 Gals 13 Fraction of Total Volume (or of a bottle) that is Usable = ( 1000 / 1050 ) - ( 1000 / 3000 ) = 0.62 Number of 11.0 Gal Total Accumulator Volume Required = / 0.62 = Gals Bottles Required Total Bottles Required = Gals / 11.0 Gals/bottle = 13.0 Bottles 13 **Fluid requirements for unit based on calculations of Table 1.0 for customers requirements of unit having accumulated control fluid under atmospheric pressure. Useable fluid of bottles is equal to 100% or more of fluid required API 16D DM Applied Machinery - 6 Station BOP Control Unit with 2 Air Remotes and Alarm Pkg Page 2 32

33 Sales Data Consolidated Pressure Control LLLP APPLIED MACHINERY 2.0 Accumulator Module E6S New carbon steel 350 gallon fluid reservoir tank. Tank complete with baffles and inspection port. Tank is designed to accommodate 6 station valve manifold, 4 way Bypass Valve with 2100 Series hydraulic pressure regulator, 4 way Annular valve with 3100 Series Failsafe, and Gauge Panel to monitor Accumulator, Manifold and Annular pressures. 2.2 (4) 4 6 Port machined steel tube bottle manifolds rated for 5000 psi working pressure. Manifold is machined from a single piece and MPI tested with certificates available. Isolation of manifold is controlled with a psi ball valve. Manifold is bled back into the reservoir through a 10,000 psi ½ needle valve. 2.3 (24) - 11 gallon 3000 psi top loading bladder type accumulators are inspected and hydro-tested to 4500 psi. UA-1 Certificates provided. 2.4 (1) - ¾ Pressure Relief valve set at 3300 psi 2.5 Module is mounted on a steel skid designed to also accommodate mounting of Primary and Secondary Pump systems. 2.6 (01) 1 Full opening valve for introduction of hydraulic pressure from an alternate pump source 3.0 Hydraulic control manifold module: Hydraulic control manifold module mounted on the accumulator unit. Consists of: A) One (01) sub plate mounted 3100 series 1 ported, low dead band pressure reducing and regulating valve for controlling annular regulated pressure. Features failsafe remote control capability through a pneumatic motor gear drive assemble and additionally provides manual adjustment at the regulator should pilot pressure for remote control be interrupted. B) One (01) Sub plate mounted 2100 series 1 ported, pressure reducing and regulating valve for controlling manifold regulated pressure to the ram type preventer and / or hydraulic actuated choke and kill line valves. This regulator is manually adjusted and limits maximum outlet pressure to 1,500 Psi during normal operation. NOTE: The regulators (patented) should be all stainless steel fitted, linear shear seal type valves with increased flow rates and 5,000 Psi rated working pressure bodies. DM Applied Machinery - 6 Station BOP Control Unit with 2 Air Remotes and Alarm Pkg Page 3 33

34 Sales Data Consolidated Pressure Control LLLP APPLIED MACHINERY C) One (01) 1 size stainless steel fitted 4-Way, 3 position manually operated rotary shear seal selector valve for controlling pressure to open and close the annular preventer. This valve will be isolated from the manifold valve circuit and received supply pressure from the annular regulator. One (1) 1 Piloted check valve on the close line to prevent closing the diverter before opening a vent line. D) Five (05) 1 Size stainless steel fitted, 4 Way, 3 position manually operated rotary shear seal selector valves rated for 3,000 Psi working pressure to control pressure to open and close ram preventers and /or hydraulic actuated choke and kill line valves. IMPORTANT The blind or blind/shear rams control valve will include a protective cover which will not inhibit remote control. BOP configuration will need to be given at time of order. E) One (01) 1 size, 3 Way, 3 position manually operated rotary shear seal selector valve rated for 3,000 Psi working pressure for operation of the manifold regulator bypass function. This valve allows selection of regulated pressure or 3,000 Psi (Full accumulator pressure) to the manifold valves for emergency operation of the ram type preventers. F) One (01) gauge panel assembly with glycerin filled, panel mount, 6 face pressure, gauges for direct indicating of: 1. Accumulator pressure (0-6,000) Psi. 2. Manifold regulated pressure (0-6,000) Psi. 3. Annular regulated pressure (0-3,000) Psi. G) One (01) 6,000 Psi working pressure manifold bleeder valve for bleeding system pressure to the reservoir when required for maintenance. H) Manifold supply piping which consist of: 1. 1 Schedule 160 main supply line ,000 psi WP T type strainer 3. 1 Schedule 160 branch lines 3.0 Primary Pump System 4.1 (1) - CPC BP4032 triplex reciprocating plunger pump; Pump has 1 ¼ plungers. Pump is specially designed for multiple HP ratings. CPC pump is equipped with a forged fluid end and crankshaft for added strength and load carrying capacity. CPC pumps come standard with Teflon/Kevlar packing, hard coated plungers and cartridge type disk valves. Pump is capable of ,000PSI DM Applied Machinery - 6 Station BOP Control Unit with 2 Air Remotes and Alarm Pkg Page 4 34

35 Sales Data Consolidated Pressure Control LLLP APPLIED MACHINERY 4.2 (1) - 25 HP Explosion Proof Motor, service factor 1.15 to allow for maximum ambient continuous running conditions of 55 C. Motor is 230/460 3 phase, 60 Hz, Nema Class 1 Div 1 on a 284T frame. Pump is unitized to triplex with a poly-chain and clog system. 4.3 (1) NEMA 7-25HP explosion proof IEC electric motor starter with 3 phase over current protection and auxiliary contact to operate Pump Running light. 4.4 System is tied into an independent Hydro-electric pressure switch set to maintain system pressure between 2750 and 3150 psi. 4.5 System is fitted on suction side with strainers, isolation valves and suction valves, and on the discharge side with a check valve rated 5000 psi. 4.6 Complete with 1 ½ Suction Valve and 20 mesh suction Y strainer and 1 5,000 Psi working pressure discharges check valve. 4.0 Secondary Pump System 5.1 (3 ea) Speeflo air pumps. These pumps deliver a 40:1 pressure ratio. The large fluid end delivers 4 gpm per pump, at optimal working pressure. Operating independently this system will allow pressuring of the unit and closing of the Annular at API 16D time requirements. Total air consumption per pump is 40 SCFM per gallon of 100 psi in. Note: Request was for (2) Air Pumps but with this BOP Stack we recommend using (3) which was quoted 5.2 System is controlled with hydro pneumatic pressure switch. This maintains unit pressure between 2750 and 3150 psi. 5.3 System suction side is regulated by a bypass gate valve and gate valves to isolate each air pump. System is plumbed on suction side with water trap and lubricator for the air, and suction valves and strainers for the fluid. Fluid discharge for each pump is plumbed with 5000 psi check valves. 6.0 Pneumatic Drillers Remote Panel for Control of BOP Closing Unit 6.1 (4 ea) ¼ Shear Seal Function Valves for Air Actuating of Annular, Pipe, Blind, Pipe. 6.2 (4 ea) ¼ Shear Seal 4 way valves for Choke, Kill, Bypass and Annular Raise and Lower 6.3 Full Graphics of BOP Stack configuration 6.4 Blind Cover 6.5 (1 ea) Master Control Valve for Permissive control of Function Valves 6.6 (2 ea) 2 ½ 0-6K Gauges. For Accumulator and Manifold Pressure 6.7 (1 ea) 2 ½ 0-3K Gauges. For Annular Pressure DM Applied Machinery - 6 Station BOP Control Unit with 2 Air Remotes and Alarm Pkg Page 5 35

36 Sales Data Consolidated Pressure Control LLLP APPLIED MACHINERY 6.8 (1 ea) 2 ½ psi gauge for Rig Air pneumatic umbilical hydraulic umbilical for Gauges 6.11 Diverter select valve. Assembly is manufactured from carbon Steel. All tubing is Stainless Steel with Brass Fittings. 7.0 Pneumatic Managers Remote Panel for Control of BOP Closing Unit 7.1 (4 ea) ¼ Shear Seal 4 way valves for Air Actuating of Annular, Pipe, Blind, Pipe. 7.2 (4ea) ¼ Shear Seal 4 way valves for Choke, Kill, Bypass and Annular Raise and Lower 7.3 Tag style remote for vale function indication 7.4 Blind Cover 7.5 (1 ea) Master Control Valve for Permissive control of Function Valves 7.6 (2 ea) 2 ½ 0-6K Gauges. For Accumulator and Manifold Pressure 7.7 (1 ea) 2 ½ 0-3K Gauges. For Annular Pressure 7.8 (1 ea) 2 ½ psi gauge for Rig Air air umbilical hydraulic umbilical for Gauges Assembly is manufactured from carbon Steel. All tubing is Stainless Steel with Brass Fittings. 8.0 Alarm Package Local and Driller - Optional 8.1 Local Alarm Panel installed on Closing Unit with Audio/Visual indication of Low Accumulator Pressure, Low Fluid Level, and Low Rig Air. Div 2 Beacon and XP Horn respond to Alarm Faults. Pilots Light on Panel indicate which condition. Alarm Silence Button stops Alarm Sounding, Beacon continues to Flash until condition returns to normal. Pilot Lights on Local Panel at Closing Unit tell what Alarm Condition is being Tripped. A N/C Float Switch, and XP Pressure Transmitter provide inputs for Alarm status. All indication local to the closing Unit. 8.2 Drillers Remote Alarm System to include three Pilot Lights to indicate Low Accumulator Pressure, Low Fluid Level and Low Air Pressure along with Alarm Silence Push Button and XP Horn. 8.3 Seven Conductor Umbilical with Amphenol connectors for connection of remote Panel to Accumulator Unit 150 for Driller Diverter Auto sequencing DM Applied Machinery - 6 Station BOP Control Unit with 2 Air Remotes and Alarm Pkg Page 6 36

37 Sales Data Consolidated Pressure Control LLLP APPLIED MACHINERY (A) One (1) each Driller s Panel assembly designed for mounting on the accumulator unit in between the annular control valve and the manifold function. Consists of: 1. One (1) each 3 way diverter select valve. 2. Two (2) each 1/4 Hydraulic shuttle valve. 3. One (1) set, dual function labels (annular/diverter, choke starboard, kill/port. Attached with thumb screws. Description of Operation 4. Two (2) each ¼ Air Shuttle valves on driller s panel 5. 1 (3,000PSI) Pilot operated Check valve to prevent premature flow to Close side of packer. (A) Diverter Mode 1. Place plugs in all B.O.P. function outlet lines except the annular, kill and choke prevent inadvertently bleeding the accumulators down during divert operations. 2. Place the mode select valve in the B.O.P. position. This bypasses the diverter automatic circuit and allows shutting the diverter in for pre-operational pressure test. 3. Place the mode select valve in the divert position. The (annular) diverter packer valve should be in the Port vent or Starboard vent position. The (kill) starboard overboard and (choke) port overboard valves will shift when the annular close line is selected. 4. When a kick is detected, the driller only has to close the diverter packer. The overboard valves will be opened automatically. The over board valves can be pre-selected at the main unit for: Port open starboard close; both open Starboard open port close. 5. The pilot operated check valve in the diverter close line prevents hydraulic pressure to the MSP until at least one overboard valve is opening. (B) B.O.P. Mode 1. Placing the mode select valve in the B.O.P. position: a. Interrupts the automatic circuit. b. Applies constant hydraulic pilot pressure to the pilot operated check valve in the annular (diverter packer) close line. This keeps the POVC open at all times permitting free flow in both directions for normal annular operation. c. The valve must be in the BOP mode to conduct testing of the diverter system. Only in this position can the packer and overboard valves be closed together. DOCUMENTATION Certificate of Origin Testing certificates as per A.P.I specification. Certificate of warranty. Spare parts catalog. Maintenance & operation manual DM Applied Machinery - 6 Station BOP Control Unit with 2 Air Remotes and Alarm Pkg Page 7 37

38 Sales Data Consolidated Pressure Control LLLP APPLIED MACHINERY Addendum This unit is manufactured at our facility in Houston Texas by technicians familiar with API closing unit requirements. All work compiled with original specifications utilizing CPC part numbers. Consolidated Pressure Control is an API 16D licensed facility. Warranty for unit is one year from commissioning into service not to exceed 18 months from delivery. This quote is acceptable from 60 days of issue date. Item Description QTY Price Station BOP closing Unit 1 117, USD 3.0 Hydraulic Manifold 1 INCL in Primary Pump System 1 INCL in Secondary Pump System 1 INCL in Drillers Pneumatic Remote 1 INCL in Managers Pneumatic Remote 1 INCL in Alarm Package Local and Driller 1 $5, Delivery: 8-10 Weeks ARO Standard Standard Int l Terms: 50% Down and Balance Due Prior to Shipment Standard Domestic Terms: Net 30 Days with Approved Credit FOB: Consolidated Pressure Control - Houston, TX Data Book: To be furnished within 3 Weeks after Shipment Validity: 60 Days Thank you, Doug Miller DM Applied Machinery - 6 Station BOP Control Unit with 2 Air Remotes and Alarm Pkg Page 8 38

39 DESIGN VALIDATION 7614 Bluff Point Houston, Texas cpcmfg.com 39

40 Design Validation APPLIED MACHINERY Design Validation: A. The above units are inspected and found to be suitable for application. B. Testing included: 1. Testing of the accumulator manifold. 2. Testing of the accumulators. 3. Testing of accumulators isolation valves and related piping. 4. Testing of the air pump. 5. Testing of the triplex pump. 6. Testing of the selector valves. 7. Testing of the regulators. 8. Testing of the unit panel to unit. 9. Testing of the gauges. 10. Testing of the pressure devices electric and hydro. Tim Thornhill API / ISO Coordinator Gary Landrum Engineer Authority DESIGN REVIEW & VERIFICATION Design review & Verification: The above serial numbered units do comply with the design review & verification. A. Tank and skid are completed and of sufficient sizing to accommodate BOP s. B. Piping, regulators, valves are sufficient for fluid volume. C. Both pumps are sufficient for volume requirements. D. Accumulators are sufficient in volume capacity to satisfy requirements. 40

41 TEST PROCEDURES 7614 Bluff Point Houston, Texas cpcmfg.com 41

42 Test Procedures APPLIED MACHINERY 42

43 Test Procedures APPLIED MACHINERY 43

44 Test Procedures APPLIED MACHINERY 44

45 Test Procedures APPLIED MACHINERY 45

46 Test Procedures APPLIED MACHINERY 46

47 Test Procedures APPLIED MACHINERY 47

48 Test Procedures APPLIED MACHINERY 48

49 Test Procedures APPLIED MACHINERY 49

50 Test Procedures APPLIED MACHINERY 50

51 SECTION 11 CERTIFICATIONS 7614 Bluff Point Houston, Texas cpcmfg.com 51

52 CERTIFICATE OF CONFORMANCE 7614 Bluff Point Houston, Texas cpcmfg.com 52

53 Certifications APPLIED MACHINERY Certificate of Compliance Unit Serial Number: 4650 Manufactured: 07/11 Tested: July 8, 2011 This 6-Station BOP Control System was assembled under the direction of Quality Control personnel familiar with current API 16D Specifications. All items and materials used in manufacture have been found to be compliant with the order and applicable 16D requirements. Upon completion of assembly this unit was tested within the Operating Pressure as prescribed by Section of Specification for Control Systems for Drilling Well Control Equipment and Control Systems for Diverter Equipment, API Specification 16D (Spec 16 D). This unit has completed and passed the Factory Acceptance Testing and is certified suitable for BOP operations. Customer: Applied Machinery Customer PO: Tim Thornhill API / ISO Coordinator T. Thornhill - Q A QA - Accepted / Approved 53

54 API CERTIFICATE 7614 Bluff Point Houston, Texas cpcmfg.com 54

55 Certifications API Certificate APPLIED MACHINERY 55

56 ISO CERTIFICATE 7614 Bluff Point Houston, Texas cpcmfg.com 56

57 Certifications ISO Certificate APPLIED MACHINERY 57

58 CERTIFICATE OF CONFORMANCE ELECTRICAL 7614 Bluff Point Houston, Texas cpcmfg.com 58

59 Certifications Electrical APPLIED MACHINERY CERTIFICATE OF CONFORMANCE ELECTRICAL Customer: Applied Machinery Customer PO: CPC Skid Number: 4650 Date of Manufacture: 07/11 Item: Multi-Station CPC accumulator electrical control system. On API listed units. Description: Electrical control system components including electric motors, sensors\ switches, control panels, and all applicable wiring, cable, seals and fittings. This document certifies that all materials manufactured for this system conform to API and IEC requirements concerning equipment for use in a hazardous area (Class 1 Div 2). Test reports covering materials and procedures used in the manufacture of CPC electrical control systems are on file and subject to examination. This Certificate of Conformance is meant to be support documentation for our Customer s Quality Assurance Department. Jeramiah Niewiadomski Service / Electrical Manager Consolidated Pressure Control, LLLP 59

60 CERTIFICATE OF WARRANTY 7614 Bluff Point Houston, Texas cpcmfg.com 60

61 Certifications Warranty APPLIED MACHINERY Certificate of Warranty This BOP Control System (aka Unit) is warranted to be free from defects in manufacture and operation for a maximum period of one year after the time of installation. The warranty coverage period is not to exceed 18 months after manufacture date. CPC may at its discretion replace or repair defective parts as needed with either entire systems/assemblies or with spare and repairs kits. If the Unit is serviced or tampered with or has been improperly installed or commissioned by persons or agencies other than certified Consolidated Pressure Control (CPC) technicians and service crews or authorized agents then this warranty may be considered void. Damage to parts through normal or anticipated wear and tear or use may is exempt from coverage. Any and all parts and systems that are to be considered for warranty and replacement must be returned to CPC for evaluation. CPC cannot be held responsible or bound for any damages resulting from mismatched electrical installation or negligence and or lack of proper service and maintenance to or misuse of the Unit and attached devices. CPC cannot be held liable for time lost, downtime, or other such losses due to equipment failures or downtime after the Unit has left our facilities. Other restrictions and limitations may apply. Please contact CPC if unclear about your warranty. DESCRIPTION: 6 - Station BOP Control System SERIAL NUMBER: 4650 MANUFACTURE DATE: July 2011 T. Thornhill - Q A QA - Accepted / Approved 61

62 CERTIFICATE OF ORIGIN 7614 Bluff Point Houston, Texas cpcmfg.com 62

63 Certifications Origin APPLIED MACHINERY CERTIFICATE OF ORIGIN This document is to hereby state that the below listed items have been manufactured and or assembled in the United States with legally available consumables that are acceptable to the governing guidelines as required for trade and export from the United States and other regulatory agencies. To the best of our knowledge, all statements made above are true and accurate. DESCRIPTION: 6 - Station BOP Control System SERIAL NUMBER: 4650 MANUFACTURE DATE: July 2011 T. Thornhill - Q A QA - Accepted / Approved 63

64 FACTORY ACCEPTANCE & HYDROSTATIC TEST CERTS 7614 Bluff Point Houston, Texas cpcmfg.com 64

65 Certifications Factory Acceptance & Hydrostatic Test Certificate Factory Acceptance & Hydrostatic Test Certificate Description: 6-Station BOP Control System Serial Number: 4650 This BOP Control System has been inspected and tested by Quality Assurance personnel and qualified technicians to our current Factory Acceptance Test standards which comply with and exceed API Spec 16D. This system has been visually and functionally tested, with remotes where applicable, and has been found to be in working and good order. Hydrostatic testing was performed to the unit in various loads and time to pressure of 4,500 PSI and 3,000 PSI throughout the system to ensure integrity. This unit has been found to be in good and working condition and is given a grade of Pass for testing purposes. Hydrostatic test results follow. T. Thornhill - Q A QA - Accepted / Approved Tim Thornhill API / ISO Coordinator July 8,

66 Certifications Hydrostatic Test Results APPLIED MACHINERY T. Thornhill - Q A QA - Accepted / Approved 66

67 Certifications Hydrostatic Test Results APPLIED MACHINERY T. Thornhill - Q A QA - Accepted / Approved 67

68 Certifications Hydrostatic Test Chard Recorder Certification 68

69 ASSORTED COMPONENT LEVEL CERTS 7614 Bluff Point Houston, Texas cpcmfg.com 69

70 Certifications Accumulator Bottles APPLIED MACHINERY CERTIFICATE OF COMPLIANCE UNIT SERIAL NUMBER: 4638 DESCRIPTION: 11 Gallon Accumulator Bottles N.B. NUMBERS: , , , , , , , , , , , , , , , , , , , , , , , NORMAL WORKING PRESSURE: 3,000 HYDROSTATIC TEST: 4,500 & 3,000 PSI - PASS DATE OF TEST: July 8, 2011 CALIBRATION ESTABLISHED BY: Gauge Calibration CAPACITY: 0-15,000PSI SERIAL NUMBER: CALIBRATED: June 13, 2011 ROOM TEMPERATURE: 70 F API / ISO COORDINATOR : TIM THORNHILL THE ABOVE INFORMATION IS FOUND SUFFICIENT FOR THIS CERTIFI- CATE OF COMPLIANCE BEING ISSUED. T. Thornhill - Q A QA - Accepted / Approved 70

71 Certifications U-1A Certification APPLIED MACHINERY 71

72 Certifications APPLIED MACHINERY 72

73 Certifications Bottle Manifolds APPLIED MACHINERY CERTIFICATE OF COMPLIANCE UNIT SERIAL NUMBER: 4650 DESCRIPTION: Accumulator Bottle Manifold SERIAL NUMBER: NORMAL WORKING PRESSURE: 3,000 HYDRO-TEST: 4,500 & 3,000 PSI - PASS DATE OF TEST: July 8, 2011 CALIBRATION ESTABLISHED BY: Gauge Calibration CAPACITY: 0-15,000 PSI SERIAL NUMBER: CALIBRATED: June 13, 2011 ROOM TEMPERATURE: 82 F API / ISO COORDINATOR : TIM THORNHILL THE ABOVE INFORMATION IS FOUND SUFFICIENT FOR THIS CERTIFI- CATE OF COMPLIANCE BEING ISSUED. T. Thornhill - Q A QA - Accepted / Approved 73

74 Certifications MPE APPLIED MACHINERY 74

75 Certifications Bottle Manifolds APPLIED MACHINERY CERTIFICATE OF COMPLIANCE UNIT SERIAL NUMBER: 4650 DESCRIPTION: Accumulator Bottle Manifold SERIAL NUMBER: NORMAL WORKING PRESSURE: 3,000 HYDRO-TEST: 4,500 & 3,000 PSI - PASS DATE OF TEST: July 8, 2011 CALIBRATION ESTABLISHED BY: Gauge Calibration CAPACITY: 0-15,000 PSI SERIAL NUMBER:37767 CALIBRATED: June 13, 2011 ROOM TEMPERATURE: 82 F API / ISO COORDINATOR : TIM THORNHILL THE ABOVE INFORMATION IS FOUND SUFFICIENT FOR THIS CERTIFI- CATE OF COMPLIANCE BEING ISSUED. T. Thornhill - Q A QA - Accepted / Approved 75

76 Certifications MPE APPLIED MACHINERY 76

77 Certifications Bottle Manifolds APPLIED MACHINERY CERTIFICATE OF COMPLIANCE UNIT SERIAL NUMBER: 4650 DESCRIPTION: Accumulator Bottle Manifold SERIAL NUMBER: NORMAL WORKING PRESSURE: 3,000 HYDRO-TEST: 4,500 & 3,000 PSI - PASS DATE OF TEST: July 8, 2011 CALIBRATION ESTABLISHED BY: Gauge Calibration CAPACITY: 0-15,000 PSI SERIAL NUMBER: CALIBRATED: June 13, 2011 ROOM TEMPERATURE: 82 F API / ISO COORDINATOR : TIM THORNHILL THE ABOVE INFORMATION IS FOUND SUFFICIENT FOR THIS CERTIFI- CATE OF COMPLIANCE BEING ISSUED. T. Thornhill - Q A QA - Accepted / Approved 77

78 Certifications MPE APPLIED MACHINERY 78

79 Certifications Bottle Manifolds APPLIED MACHINERY CERTIFICATE OF COMPLIANCE UNIT SERIAL NUMBER: 4650 DESCRIPTION: Accumulator Bottle Manifold SERIAL NUMBER: NORMAL WORKING PRESSURE: 3,000 HYDRO-TEST: 4,500 & 3,000 PSI - PASS DATE OF TEST: July 8, 2011 CALIBRATION ESTABLISHED BY: Gauge Calibration CAPACITY: 0-15,000 PSI SERIAL NUMBER: CALIBRATED: June 13, 2011 ROOM TEMPERATURE: 82 F API / ISO COORDINATOR : TIM THORNHILL THE ABOVE INFORMATION IS FOUND SUFFICIENT FOR THIS CERTIFI- CATE OF COMPLIANCE BEING ISSUED. T. Thornhill - Q A QA - Accepted / Approved 79

80 Certifications APPLIED MACHINERY 80

81 Certifications Valve Manifolds APPLIED MACHINERY CERTIFICATE OF COMPLIANCE UNIT SERIAL NUMBER: 4650 DESCRIPTION: Valve Manifold SERIAL NUMBER: NORMAL WORKING PRESSURE: 3,000 HYDRO-TEST: 4,500 & 3,000 PSI - PASS DATE OF TEST: July 8, 2011 CALIBRATION ESTABLISHED BY: Gauge Calibration CAPACITY: 0-15,000 PSI SERIAL NUMBER: CALIBRATED: June 13, 2011 ROOM TEMPERATURE: 82 F API / ISO COORDINATOR : TIM THORNHILL THE ABOVE INFORMATION IS FOUND SUFFICIENT FOR THIS CERTIFI- CATE OF COMPLIANCE BEING ISSUED. T. Thornhill - Q A QA - Accepted / Approved 81

82 Certifications MPE APPLIED MACHINERY 82

83 Certifications Tank/Skid APPLIED MACHINERY CERTIFICATE OF COMPLIANCE UNIT SERIAL NUMBER: 4650 DESCRIPTION: Tank, Skid, Manifolds, Motor Brackets, and other welded components. UNIT SERIAL NUMBERS: 4650 NORMAL WORKING PRESSURE: 3,000 HYDRO-TEST: 4,500 & 3,000 PSI - PASS DATE OF TEST: July 8, 2011 CALIBRATION ESTABLISHED BY: Gauge Calibration CAPACITY: 0-15,000 PSI SERIAL NUMBER: CALIBRATED: June 13, 2011 ROOM TEMPERATURE: 82 F API / ISO COORDINATOR : TIM THORNHILL THE ABOVE INFORMATION IS FOUND SUFFICIENT FOR THIS CERTIFI- CATE OF COMPLIANCE BEING ISSUED. T. Thornhill - Q A QA - Accepted / Approved 83

84 Certifications MPE APPLIED MACHINERY 84

85 85

86 ASSEMBLY PRODEDURES & MANUFACTURING CHECKLIST FOR CPC DESIGN BOOKS ONLY 7614 Bluff Point Houston, Texas cpcmfg.com 86

87 THINGS TO KNOW BEFORE USING 7614 Bluff Point Houston, Texas cpcmfg.com 87

88 APPLIED MACHINERY THINGS TO KNOW BEFORE USING Location & Positioning When moving the unit always make certain that OSHA and other applicable safety rules, laws and regulations are followed as to prevent and minimize the potential of injury or death to persons and to reduce damages to the System and other equipment. The System should be approximately 100 feet from the well bore. Some condition and applications may cause this to vary; however a suitable distance for safety should be priority. Last resort in a blowout condition is to shut the well in manually from the accumulator unit. If the System is located closer to the well bore run a higher risk of injury under these extremely dangerous condition. Locate and position the unit in safe area as not to interfere with other operations. Keep the unit clear of areas where water/liquid run-off and leakage may be considered an issue. Make sure the System is carefully seated on a level surface prior to connecting and or using the device. There is sufficient room under the skid to pick up the system to allow safer and simplified moving/arrangement of this unit prior to and after use. Never allow any person to stand, move or work underneath or on the equipment or in any area that it may fall onto while it is raised or in motion. Never attempt to power-up or run the System when positioning, suspending, or moving. If and when hoisting/lifting always make certain there is a trained spotter dedicated to aiding the crane/hoist operator. Never allow any person to stand, move or work underneath or on the equipment or in any area that it may fall onto while it is suspended or in motion. Whenever lifting or suspending the System it is required that it is a affixed and is balanced. This system s approximate weight will vary. Make sure forklift or crane operator knows the weight of load before moving. All lifting equipment must be rated to exceed that weight requirement by the minimum Safety Factor that is required (typically 2X). Always inspect the lifting equipment to insure it is without damage and that all points are firmly connected and remain connected during the hoisting/suspension process. Once the System is in place, make certain that there is adequate room all the way around the equipment to allow for access to the system as well as safe passage for exit in the event of an emergency. Verify that the hose is capable of reaching the targets it must mate with and the unit simultaneously. Remove all rigging from unit and any clutter in the area. 88

89 THINGS TO KNOW BEFORE USING Identify Nameplate The Customers System should be identified with a nameplate on the Accumulator system. This allows any individual to understand what key features are on the Accumulator system. On all CPC nameplates there will be a Primary Pump Source, which includes the Triplex Size and the Motors Horse Power. Then it will tell you the Secondary Pump, which will give it a API monogram and also list the Air pump ratio and amount of air pumps on Accumulator system. The nameplate identifies the type of remote that runs with the Accumulator system. Every Accumulator system varies so the nameplate will identify the Tank size and Usable fluid allowed. CPC also shows on the nameplate that the Accumulator bottles are set to a Pre-charge pressure. With any system in the industry there is a working pressure, on CPC systems the normal working pressure is listed on the nameplate. CPC EXAMPLE NOT FOR USE 89

90 UNDERSTANDING KEY COMPONENTS 7614 Bluff Point Houston, Texas cpcmfg.com 90

91 UNDERSTANDING KEY COMPONENTS ON A BOP ACCUMULATOR SYSTEM Accumulator System This System is equipped with many key components and connection that will need to be identified by all mechanics/engineers working with or on the BOP Unit. (See pages 9 & 10) Use the Glossary at the back of the manual for definitions on key components when needed. There are two basic components on the unit. The Main BOP Control System, also commonly called the accumulator. The second is the HMI Touchscreen Remote with umbilical connection (Quantity of remote varies with customer request). The Accumulator is the main high-pressure hydraulic supply for the blowout preventer stack. It will be the main component for the control of the BOP system. The Accumulator will store all fluid needed to control BOP Stack. Each accumulator is equipped with the combination of electric and air operated hydraulic pumps depending on customer request. These pumps discharge high-pressure hydraulic fluid into accumulator bottles. The bottles are filled with compressed nitrogen gas. When fluids enter the bottles the nitrogen is then compressed and gives off a great amount of potential energy. 91

92 UNDERSTANDING KEY COMPONENTS ON A BOP ACCUMULATOR SYSTEM Diverter Panel This System is equipped with a diverter system, which is usually used during top-hole drilling and in conjunction with marine riser systems. The diverter is a annular sealing device used to close and pack-off the annulus around pipe. It provides a low-pressure flow control system to direct controlled or uncontrolled wellbore fluids away from the immediate drilling area, it is not intended to shut-in or halt well flow. The use is primarily used for the potential hazardous flow that can experience prior to setting the casing string on which the BOP stack and choke manifold will be installed. Some diverter systems are designed to function as diverter and BOP. The diverter application consists of an annular sealing device, vents, vent lines, valves and a control system. The control system will be equipped with a panel assembly that controls the diverter, also know as diverter mode. The diverter control system is usually hydraulic or pneumatic, or a combination of both types, which may be electrically controlled and capable of operating the diverter system from two or more control units. 92

93 UNDERSTANDING KEY COMPONENTS ON A BOP ACCUMULATOR SYSTEM Accumulator Remote Control Panel (Pushbutton Remote Panel) The pushbutton control panels are provide for operation of blowout preventer control systems from locations other than the hydraulic control manifold. Each control panel is manufactured to customer s requirements and although physical size and number of controls may vary. All panels will use identical components and operate in the same manner. The pushbutton control panel is usually located on the rig floor. These panels feature a lamp representation of the blow out preventer stack and contain control valves to duplicate the functions of the hydraulic control manifold. In addition, the pushbutton control panels also provide alarms and gauges to monitor BOP control system pressures. 93

94 UNDERSTANDING KEY COMPONENTS ON A BOP ACCUMULATOR SYSTEM FIGURE - 1 FIGURE 1- RIGHT SIDE OF BOP CONTROL SYSTEM A. Air Pump Y Strainer (CLEAN MONTHLY) B. Air Pump Suction Line Valve C. Air Pump Isolation Valve (NORMALLY OPEN) D. Reservoir View/ Fill Port E. Oil Air Lubricator (L/S) Air Filter (R/S) F. Hydraulic Fluid Reservoir (AKA Tank) G. Bottle Manifold Pressure Gauge Isolation Valve H. Bottle Manifold Bleeder Valve I. Bottle Manifold Isolation Valve J. Bottle Manifold Pressure Gauge K. Annular Regulator L. Valve Manifold Bleeder Valve M. Air Pumps N. Starter Box 94

95 UNDERSTANDING KEY COMPONENTS ON A BOP ACCUMULATOR SYSTEM FIGURE - 2 FIGURE 2- LEFT SIDE OF BOP CONTROL SYSTEM O. By-Pass Accumulator P. Low Pressure / High Pressure By-Pass Lever Q. By-Pass, Manifold, Annular Gauges R. 4-Way Selector Valve S. Electric Box T. Limit Switches U. Electric Motor V. Triplex Pump W. Triplex Y Strainer Pressure Relief Valve (PRV) X. Pressure Relief Valve (PRV) Bottle Manifold Isolation Valve Y. Bottle Manifold Isolation Valve Z. Bottle Bank Pressure Gauges AA. Accumulator Bottles AB. Electric Pump Suction Valve Line 95

96 INSTALLING BOP ACCUMULATOR SYSTEM 7614 Bluff Point Houston, Texas cpcmfg.com 96

97 INSTALLING BOP ACCUMULATOR SYSTEM Initial Plumbing and Air Hookup An Accumulator has plumbing connections (BOP stack lines), which are located on the backside of the system. There are twelve (12) 1 NPT connections on this system. (See figure below) The hoses/lines needed to be rated 5000psi or greater and must be fire resistant according to governing specifications. The Accumulator is designed to be operated at the unit or remotely. Connect the air hose to the air supply port also located on the back of the system (will be marked visibly AIR ) with a 1-1/2 NPT fitting. 1-1/2 AIR NPT PORTS 1 NPT PLUMBING PORTS 97

98 INSTALLING BOP ACCUMULATOR SYSTEM Filling Reservoir and Pre-charge is Recharged Inspect reservoir by opening the 4 inspection/fill ports ( Key Components figure 1/ item D)and make sure the reservoir is free of any debris that could contaminate the system. A clean reservoir reduces maintenance. After inspected proceed to fill the reservoir by the same 4 inspection/fill port ( Key Components figure 1/item D) and fill reservoir to 8 from the top. This should be biodegradable 10wt hydraulic oil or the equivalent. If water\glycol mixture is desired consult factory on flushing procedures. Verify that there is no pressure in bottle manifold and then operator can confirm that each Bottle ( Key Components figure 2/item N) and gauge assembly ( Key Components figure 1-2/item J-Z) is recharged at 1,000psi +\- 10%. If nitrogen is low, then fill bottle to 1,000psi. DO NOT ATTEMPT TO CHARGE SYSTEM WITHOUT NITROGEN BLAD- DERS. NEVER USE ANY OTHER GASES OTHER THAN DRY NITROGEN. Test the Pre- Charge of the accumulator bottles by opening the bleeder valve on the valve manifold ( Key Components figure 1/item L) and open the shut off valve on the accumulator bottle banks ( Key Components figure 1/item H) before checking the nitrogen pre-charge pressure. Remove the guard from the valve stem on the accumulator bottle and attach the charging and gauging assembly. First, screw in the gauge and then screw down the T handle to check the nitrogen pre-charge in the accumulator bottle. The gauge pressure should read 1,000psi +\- 10%. If the pre-charge is low, add nitrogen utilizing the charge and gauging assembly to 1,000psi +\- 10%. Check the valve stem for leaks after filling. 98

99 INSTALLING DRILLER REMOTE 7614 Bluff Point Houston, Texas cpcmfg.com 99

100 INSTALLING DRILLER REMOTE Connecting Electrical Power This Unit is equipped with a 25-horse power 3-phase explosion proof motor with thermal overload protection. Motor is 480 volts, 60hz and is rated at 40 degrees Celsius ambient temperature. The motor has been pre-wired to the starter switch located in the starter box (visible from the front Unit). On the top rear of the Starter Box (Figure 1), there is a 1-1/4 NPT plug that can be removed to allow for wiring from rig power to the starter switch. Only certified/qualified electrical workers are authorized to wire the unit. Before engaging/activating power make certain the wiring and the unit are properly grounded and the unit for electrical current in the skid/frame assembly prior to allowing any personnel to operate the equipment and prior to connecting it to any other equipment. A. 1-1/4 NPT orrifice for electrical power supply (480 V) located on top rear of Starter Box Starter Box is made of aluminium. Do not overtighten or cross thread.! Figure 1 - Wiring 480V Electrical Connection CAUTION HIGH VOLTAGE A Inside the PLC (PANEL) there will be an 110V connection that will be hooked up shown in Figure 2. This will allow the PLC to have power. If the PLC loses power the PLC will continue to run for two hours on the UPS battery pack up system. Figure 2 - Wiring 110V 100

101 INSTALLING DRILLER REMOTE Getting Started 1) Visually inspect pushbutton for any defects from shipping 2) Next install your pushbutton in a Division 1/2, or safe area depending on rating. It should be kept out of direct sunlight in order to view properly during the day. Note: Should be mounted in easily assessable location to driller under any drilling conditions. 3) If using this guide for rig moves, operator should inspect all Amphenol connectors to make sure pins have not corroded or pushed back into connector. 4) Connect your pushbutton to local PLC panel on unit via your custom umbilical. Note: If you have more than one pushbutton you will need to confirm it is connected to the proper port, driller s will be the connector on the left, or the top depending on layout. 5) If needed extensions are available from CPC. For systems designed around Ethernet communications, distances over 330 feet should first be consulted with the factory. 101

102 INSTALLING DRILLER REMOTE Powering Up PLC 1) Power to your remote control panel is supplied via the CPC custom umbilical, and is connected to a battery back-up system suitable for up to 2 hours of operation. 2) To turn the power on, there is a selector switch located on the main unit PLC control panel. (Off-Charge-on) Turn to On 3) When power is supplied to the panel, but you do not want the re mote, and PLC to come on use the Charge position to allow the batteries to continue to charge. Placing the switch in off disconnects the batteries, and the power supply. 102

103 INSTALLING DRILLER REMOTE Start up on Pushbutton Panel 1) Once your local panel is in the On Position it will allow power to be sent to the Remote. 2) Since the pushbutton is working off a windows based program it will need a few seconds to boot up. 3) Alarms will be sounding once the unit is energized, the operator will be able to silence them momentarily. 4) The remote operator can silence alarm at unit or screen. 5) Press the Alarm silence\reset button. (This will shut off the buzzer until a new alarm is present) Remote Alarm Reset PLC Alarm Reset 103

104 INSTALLING DRILLER REMOTE Identifying Correct Configuration and using Two Hand operation 1) As a safety precaution, a two handed control is necessary to operate the HMI for complete awareness of valve shifting. Anyone operating the HMI should be well trained and very aware of any functions when shifting a valve. 2) To Shift a valve you must first hold down the Master Permissive Pushbutton located at the bottom\left of the HMI Screen, and then you may press any of the valves Open\Close tabs on the HMI. Some remote will also have a protected cover that will need to be lifted before operation can be done. Valve shifting will be non-functional unless you press the MPP. There will be a few second delay from the HMI to the BOP. 104

105 INSTALLING DRILLER REMOTE Identifying Correct Lamp Illumination 3) Once an Open or Close tab is pressed with the master permissive button; a lamp will illuminate assuring you the valve shifted to correct location. Make sure the operator know exactly when shifting a valve what each valve does. For it is very critical and could seriously jeopardize the operation. CPC recommends extensive training for any operator using the pushbuton or BOP. 105

106 INSTALLING DRILLER REMOTE Understanding Shear Ram Operation 4) When shifting a Covered Shear Ram a extra three (3) second delay will be utilized to show if the operator is sure they want to open or close the valve. There will be a alarm sounding when the cover is lifted on the remote. Only shift valve when appropriate time is permitted. Note: Putting the valve in Block position is a manual function and not done on the pushbutton, that valve will be shown with no lamp color on the representing valve. 106

107 INSTALLING DRILLER REMOTE Raising and Lowering Annular 5) To raise or lower the annular pressure hold the Master Permissive Button and momentarily press the raise or lower tabs, there will be a few second delay before the gauge displays the new value so adjust it in short increments. 107

108 STARTING AND OPERATION 7614 Bluff Point Houston, Texas cpcmfg.com 108

109 STARTING AND OPERATION Initial Procedure for Operating BOP Accumulator To start the initial operation and start up the operator will need to center all four-way control valves into the block or middle position. ( Key Components figure 2/ item R) Move the By-Pass valve ( Key Components figure 2/ item P) to the left which is the low pressure 1,500psi. Close the Bleeder valve or valves on the Upper Valve Manifold (Key Components figure 1/item L). Open ALL systems suctions valves electrical (Key components figure 2 / AB) and air ( Key Components figure 1/item A), this will then allow pumps to have access to the hydraulic fluid. Check to be sure the accumulator bottle rack shut-off valves are open. (Key Components figure 1/ item I, Key Components figure 2/ item Y) BY-PASS LOW BLEEDER VALVE Open the air valve to each pump ( Key Components figure 1/item M) and independently check the operation of each pump by viewing return to tank line for flow. Most field operation recommends all air pumps to be open for proper pressuring. Each Unit is supplied with an appropriate amount of air pumps, which depends on fluid capacity or customer request. Use the air pumps to apply pressure to system gradually, checking for leaks as system raises pressure. Raise it to approximately 1,200psi. While checking all the lines, fitting and connections of leaks. 109

110 STARTING AND OPERATION Using Motor Correctly Turn the motor starter switch ( Key Components figure 2/item T) on the triplex pump to the OFF positions and connect the correct electrical power line. Check oil level in the triplex crankcase to make sure it is full with SAE 80/90 wt ( Key Components figure 2/item V) engine oil. Oil will change with ambient temperature. REFER TO OIL CHART FOR CPC PUMP IN PARTS SECTION. The triplex pump will pressure in either direction, but failure to run in proper direction will cause lubrication problems internally. Which also cause pre mature failure. If triplex pump does not bring system up to pressure refer to the Priming a CPC triplex pump trouble shooting guide on how to prime triplex pump. Turn switch left is HAND mode Turn switch right is AUTO mode OFF HAND AUTO Always make sure the bottles isolation valve are in the open position. Turning on the motor starter switch on the triplex pumps to Auto will charge the accumulator bank until the accumulator pressure reads 3,000psi. The automatic pressure switch controls the electric pump module and is adjustable to shut off the pumps at 3,000psi and to restart when fluid pressure drops below 2,700psi. The electric pump will autostart when the control is in Auto supplying power. At all time during operations one module must be in a active stat via its source of power. There are gauge readings ( Key Components figure 2/ item Q) calibrated with -0- reading, gauge adjustments should not be required. There is also a Pressure Relief Valve ( Key Components figure 2/item X) set to 3,300psi to prevent system from over pressurization. API REQUIRES THAT CHARGING OF SYSTEM WITH BOTH PUMPING SYSTEMS TAKE LESS THAN 15 MINUTES. 110

111 STARTING AND OPERATION Correct Belt Rotation Make sure the Motor and the Pump are rotating in a counter-clockwise orientation as shown below by momentarily activating/bumping the power switch in the front of the starter box. The timing belt is moved by the crank shaft throwing oil to the top towards the fluid end to lubricate rod slides. Which will then give the rotation between the motor and triplex. If not, swap wires as needed until the correct rotational direction is achieved. Verify Correct Motor & Pump Rotation during Electrical Connection A! CAUTION HIGH VOLTAGE Rotation B C Rotation D A. Starter Box B. Electric Motor C. Triplex Pump D. Belt Cover 111

112 STARTING AND OPERATION Priming a CPC Triplex Pump Occasionally the triplex pump(s) on a BOP Closing System may require priming in order to work correctly. This may occur with new units after shipping, when a unit has been left/stored for a period of time without operation, following a drain and inspection of the tank. The above scenarios are typical of times when the Hydraulic Fluid Reservoir has been drained. There may also be other situations in which the pump may require priming and the following two (2) methods can be used to prime the unit. Simple Measures Prior to performing either of the Options for Triplex priming, please sure to make sure each of the following have been performed: A. Make sure there is hydraulic fluid in the reservoir tank. B. Make Certain the shut-off valve between the tank and pump is in the On/Open position to allow fluid to flow to and through the triplex. C. Make certain that electric power is enabled to the system to allow the motor to run. D. Verify that when the motor is running, the pump is rotating as well. Only do this by bumping the motor/pump momentarily using the Hand On option on the starter box. 112

113 STARTING AND OPERATION Priming a CPC Triplex Pump OPTION A The Simple Method This method is not going to work all of the time but it works in many instances. Step A-1 Remove the plug on the top side of Fluid End Module Step A-2 Place/Hold a bucket near the unplugged fluid end (to capture discharged fluid) and momentarily turn the electric motor to that pump on. Let it run for about 5-20 seconds to allow Hydraulic Fluid to travel through the Module and escape into the bucket. You may try this process only as couple of times. If this method works oil will begin to shoot out of the open port. If oil does exit the port shut the power to the motor off and quickly replace the plug into the port and tighten appropriately. If this method does not work then proceed with the next method, Option B. 113

114 STARTING AND OPERATION Priming a CPC Triplex Pump OPTION B The Longer Method If Option A did not work, and there is fluid in the tank, the valve is open and the power is working then this method should work correctly to prime the pump. It requires a few more steps but is relatively simple. Tools required for this operation include a wrench that fit the nuts on the top of the pump (they vary in sized based upon the pump model/size), a lifting eye or puller stud (size dependent upon the pump model), a magnetic pick-up bar, and a torque wrench. Step B-1 Remove the three (3) bars that act as the Clamp/Hold Downs to the valve Covers Step B-2 Remove the Covers. This is best done using a lifting eye. 114

115 STARTING AND OPERATION Priming a CPC Triplex Pump OPTION B The Longer Method Step B-3 Remove the Spring, the Cage, and the Upper Disc Valve from each of the three exposed ports. Fill Cavity (plunger) with oil and reassemble. Removing Spring from 1 of the 3 Removing Cage from 1 of the 3 Removing Upper Disc Valve from 1 of the 3 115

116 STARTING AND OPERATION Priming a CPC Triplex Pump OPTION B The Longer Method Step B-4 With each of the three (3) ports now clear of the springs, cages and upper valves, it is now time to open the Lower Disc Valve (not shown) and fill the port cavity with hydraulic oil. The best way to do this is to go port by port with a magnetic pick-up tool. Insert the magnetic bar into the open port and through the Seat until it contacts the Lower Disc Valve. With the magnet engaged to the lower disc valve, carefully pull up on the lower valve to lift it up. With the valve lifted up the hydraulic fluid should begin to fill the cavity. This fluid is travelling through the lower portion of the Fluid Module from the Reservoir/Tank so it is important to make sure the Shut-Off Valve (shown in the Simple Measures section) is in the Open position. Once enough oil has filled the cavity pull up firmly on the magnetic bar to disengage the magnet from the valve and allow the valve to reseat. After one cavity fills, move on the next cavity and repeat this step for each of the three (3) cavities. Step B-4 is complete when each of the cavities is full as shown to the right. 116

117 STARTING AND OPERATION Priming a CPC Triplex Pump OPTION B The Longer Method Step B-5 Once each of the cavities is full, replace the Upper Disc Valve, Spring, Cage and Cover into each of the ports.. Be sure to place the Disc Valve correctly onto the seat. When installing the Cover take care not to damage the O-Ring and to insert the cover in a straight manner. Do this to each of the ports. Step B-6 After the ports are re-equipped and covered it s time to place the Clamp/Hold-Down bars on them. Be sure to evenly seat the bar on the cover by alternating back and forth from one stud, to the next, repeat. DO NOT TIGTHEN DOWN ON ONE STUD AT A TIME. Evenly distribute the force by alternating back and forth between each of the two studs per port. Use a torque wrench for this step and be sure to tighten the studs and nuts to the correct torque. For correct torque values refer to the Pump Manual (typically in the BOL/Parts List sections) 117

118 STARTING AND OPERATION Operation of Nitrogen Back-up System (customer option ) This unit is equipped with a nitrogen backup system. It is used as a last resort pressure source in the event you lose all accumulated pressure, and primary pumping systems. These systems typically have a reserve of 2,200psi. 1. Check to make sure the nitrogen bleed off valve is in the closed position. 2. Open the nitrogen isolation valve at the top of all nitrogen bottles, as well as isolation valve after the T leading into the Accumulator piping. There is a check valve in line of the piping system before it reaches Accumulator piping, as long as nitrogen pressure exceeds accumulator pressure it will continue to add pressure to the BOP control system. If possible, close accumulator bottles before engaging nitrogen system to prevent loss of nitrogen into the accumulator bottles. 3. Once nitrogen is used to close well in it should be manually shut in on the BOPs, until primary pump systems can be repaired, or brought back into service. 4. Maintenance A.) Bottle pressures should be checked monthly to ensure the maximum amount of nitrogen is available in the nitrogen reserve in the event of failure of the primary pumps. (See checking bottle pressure below) B.) Visual inspection of bottles and hoses should be done every time pressure is checked. Worn or damaged bottles should be replaced immediately. 5. Check bottle pressures A.) Close off isolation valve after T, open bleeder valve to relieve any pressure trapped in lines. B.) Close bleeder valve C..) Open Nitrogen bottle D.) Record pressure. E.) Close nitrogen bottle F.) Open bleeder valve, relieve pressure, close bleeder valve. 118

119 OPERATING THE DIVERTER MODE 7614 Bluff Point Houston, Texas cpcmfg.com 119

120 OPERATION APPLIED MACHINERY Operation of Diverter Mode Diverter Mode 1. Place plugs in all B.O.P. function outlet lines except the annular, kill and choke prevent inadvertently bleeding the accumulators down during divert operations. 2. Charge accumulator unit to full pressure (3,000psi) via pumping system. 3. Place Annular in the open position, and Choke & Kill Lines in the closed position. Overboard preselect valve should be in the block or Both position. FRONT VIEW OVERBOARD PRE-SELECT MODE SELECT PORT BOP STARBOARD BOP DIVERTER ANNULAR / PACKER OPEN CLOSE OPEN KILL/PORT CLOSE CHOKE/ STARBOARD OPEN CLOSE MODE SELECT IN DIVERTER WITH ANNULAR IN OPEN CHOKE & KILL IN CLOSED 4. From the unit manually place system in the Divert mode via BOP/Divert manipulator valve DIVERTER FRONT VIEW DIVERTER FRONT VIEW OVERBOARD PRE-SELECT MODE SELECT OVERBOARD PRE-SELECT MODE SELECT PORT BOP STARBOARD BOP DIVERTER PORT BOP STARBOARD DIVERTER BOP MODE SELECT DIVERTER MODE MODE SELECT DIVERTER MODE 120

121 PORT PORT BOP OVERBOARD PRE-SELECT BOP STARBOARD STARBOARD BOP BOP MODE SELECT DIVERTER DIVERTER PORT PORT BOP OVERBOARD PRE-SELECT BOP STARBOARD STARBOARD BOP BOP MODE SELECT DIVERTER DIVERTER OPERATION APPLIED MACHINERY Operation of Diverter Mode 5. Closing the annular valve both Overboard valves will open. 6. Opening the annular valve both Overboard valves will close FRONT VIEW FRONT VIEW OVERBOARD PRE-SELECT MODE SELECT OVERBOARD PRE-SELECT MODE SELECT ANNULAR / PACKER OPEN CLOSE ANNULAR / PACKER OPEN CLOSE OPEN KILL/PORT CLOSE CHOKE/ STARBOARD OPEN CLOSE OPEN KILL/PORT CLOSE CHOKE/ STARBOARD OPEN CLOSE MODE SELECT IN DIVERTER WITH ANNULAR IN CLOSED CHOKE & KILL IN OPEN MODE SELECT IN DIVERTER WITH ANNULAR IN OPEN CHOKE & KILL IN CLOSED 7. With annular valve in the close position, valves should be air locked, and unable to shift. 8. Place overboard preselect in the Port position. 9. When the annular valve is closed the port Overboard valve opens. 10. Opening the annular valve the Port Overboard valve closes. 11. With annular valve in the close position the Port overboard valve should be air locked, and unable to shift. DIVERTER FRONT VIEW DIVERTER FRONT VIEW ANNULAR / OPEN PACKER CLOSE ANNULAR / OPEN PACKER CLOSE OPEN KILL/PORT CLOSE CHOKE/ STARBOARD OPEN CLOSE OPEN KILL/PORT CLOSE CHOKE/ STARBOARD OPEN CLOSE OVERBOARD IN PORT POSITION ANNULAR CLOSED OVERBOARD KILL/PORT OPENS OVERBOARD IN PORT POSITION ANNULAR OPEN OVERBOARD KILL/PORT CLOSES 121

122 PORT OVERBOARD PRE-SELECT BOP STARBOARD BOP MODE SELECT DIVERTER PORT BOP STARBOARD BOP DIVERTER OPERATION APPLIED MACHINERY Operation of Diverter Mode 12. Next, shift overboard preselect valve to starboard valve; which the starboard valve should open and the Port valve closes. 13. Then open annular valve and confirm that Starboard Overboard valve closes. 14. Close the annular valve and confirm that Starboard Overboard valve opens 15. With annular valve in the close position, try to close the Starboard overboard valve. Valves should be air locked, and unable to shift. DIVERTER FRONT VIEW DIVERTER FRONT VIEW ANNULAR / OPEN PACKER CLOSE ANNULAR / OPEN PACKER CLOSE OVERBOARD PRE-SELECT MODE SELECT OPEN KILL/PORT CLOSE CHOKE/ STARBOARD OPEN CLOSE OPEN KILL/PORT CLOSE CHOKE/ STARBOARD OPEN CLOSE OVERBOARD IN STARBOARD POSITION ANNULAR CLOSED STARBOARD OPENS PORT CLOSES OVERBOARD IN STARBOARD POSITION ANNULAR OPEN STARBOARD CLOSES PORT STAYS IN CLOSE 16. Shift Manipulator valve back into BOP position FRONT VIEW OVERBOARD PRE-SELECT MODE SELECT PORT BOP STARBOARD BOP DIVERTER ANNULAR / PACKER OPEN CLOSE OPEN KILL/PORT CLOSE CHOKE/ STARBOARD OPEN CLOSE MODE SELECT IN BOP 122

123 OPERATION APPLIED MACHINERY Operation of Diverter Mode 17. Remote testing of Diverter auto sequencing functions will be same except below notes and it will be labels on. NOTES: During testing from remotes, confirm that pilot lights illuminate properly with the actions being taken. When using remotes, be sure to hold functions long enough for actions to execute (Approximately 10 seconds) each function requires Master pushbutton to be pressed while shifting functions. Overboard preselect shifting function only available on driller remote. Confirm pilot lights on other remotes. 123

124 RIGGING DOWN OPERATION 7614 Bluff Point Houston, Texas cpcmfg.com 124

125 RIGGING DOWN OPERATION Initial Procedure for Rigging Down BOP Accumulator To end operation and rig down the accumulator system, the operator will need turn all air valves in the close position and turn the motor starter switch on the triplex pumps to OFF giving the accumulator no charge or air. For safe practice of lock out tag out the operator should unhook the 480V from the starter. The operator will need to make sure that this is complete before any hydraulic can be released back into the tank. If these steps are not done hydraulic will not be released. Close off the main air suction line (Key Components figure 1/ item B) once all the hydraulic is back into tank. The operator can then open one air valve to release any remaining pressure in the air pump lines. Then re-close the air valve on the remaining open-air valve. (Key Components figure 1/ item M) Put all four-way control valves back into the block or middle position. (Key Components figure 2/ item R). Move the By-Pass valve (Key Components figure 2/ item P) to the left, which is the low-pressure 1,500psi. Open the bleeder valve or valves on the Upper Valve Manifold (Key Components figure 1/item L), doing so will allow the hydraulic to be released from the bottle and valve manifolds and return to tank. Check to be sure the accumulator bottle rack shut-off valves are still open. (Key Components figure 1/ item I, Key Components figure 2/ item Y). These will never close in starting or rigging down operation. The very last step the operator will need to complete will be turning off the HMI touch screen from the PLC box. Keeping this on until the last step if for purpose of having visual that all alarms and components on the accumulator system have been shut off or down properly. Following all these step will make for a safe easier disconnect from the BOP stack. If all hydraulic is drained back into system the quick connect lines can be disconnected from BOP stack. ONLY IF ALL HYDRAULIC IS IN ACCUMULATOR TANK SYSTEM AND DISCHARGE LINES ARE COMPLETELY DRAINED. NOTE - During these step the alarms will sound, check them accordantly and then press the alarm-reset button from screen or PLC. 125

126 MAINTENANCE AND MAINTIAING BOP ACCUMULATOR SYSTEM 7614 Bluff Point Houston, Texas cpcmfg.com 126

127 MAINTENANCE AND MAINTAINING ACCUMULATOR SYSTEM A regular scheduled maintenance program must be developed to sufficiently maintain the BOP Accumulator Control System. The operator must develop the appropriate program based on his operating, testing and drilling programs. The entire control system should be tested a minimum of once a week. This may simply involve operating all functions (remotely as well as from the unit) and noting gauge readings. Good maintenance programs must be developed whether the operator chooses a very simple or very thorough test program. CPC has also listed with tags on key items that need to be checked or cleaned. The following items should be maintained on a monthly basis until the operator can develop a suitable program based on his or her specific operating and testing. Pressure Gauges Close attention should be paid to the unit s pressure gauges reading specific pressure readings. Example, (the low side of manifold pressure gauge should read 1,500psi. Whereas the high side should reflect 3,000psi.) Check for cracks and damage. 127